Related Manuals for Fronius VR 1500
Summary of Contents for Fronius VR 1500
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions VR 1500 Spare parts list VR 1500 PSA Wire-feed unit VR 1500 - 11 VR 1500 - 12 VR 1500 - 30 VR 1550 VR 1550 CMT-WS 42,0426,0006,EN 005-18032019...
- Page 3 Thank you for the trust you have placed in our company and congratulations on buying this high-quality Fronius product. These instructions will help you familiarise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer.
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Page 5: Table Of Contents
Controls, connections and mechanical components.................. General remarks ........................... Front of wirefeeder..........................Rear of wire-feed unit..........................Notes regarding the operation of the VR 1500 - 11 and VR 1500 - 12 ............Cooling the wirefeeder motor........................ Welding current above 500 A........................ PMR 4000 push-pull option........................ - Page 6 General remarks ........................... VR 1500 ..............................VR 1500 - 11............................VR 1500 - 12............................VR 1500 - 30............................VR 1550 (CMT-WS)..........................Appendix Spare parts list: VR 1500, VR 1550 ......................Circuit diagrams: VR 1500, VR 1500 PSA, VR 1550 .................
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Page 7: Safety Rules
Safety rules General The device is manufactured using state-of-the-art technology and according to recognised safety standards. If used incorrectly or misused, however, it can cause: injury or death to the operator or a third party, damage to the device and other material assets belonging to the operating company, inefficient operation of the device. -
Page 8: Obligations Of The Operator
Ambient temperature range: during operation: -10 °C to + 40 °C (14 °F to 104 °F) during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F) Relative humidity: up to 50% at 40 °C (104 °F) up to 90% at 20 °C (68 °F) The surrounding air must be free from dust, acids, corrosive gases or substances, etc. -
Page 9: Protecting Yourself And Others
Protecting your- Anyone working with the device exposes themselves to numerous risks, e.g. self and others flying sparks and hot pieces of metal Arc radiation, which can damage eyes and skin Hazardous electromagnetic fields, which can endanger the lives of those using cardi- ac pacemakers Risk of electrocution from mains current and welding current Greater noise pollution... -
Page 10: Danger From Flying Sparks
The relevant material safety data sheets and manufacturer's specifications for the listed components should therefore be studied carefully. Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area. Danger from fly- Flying sparks may cause fires or explosions. ing sparks Never weld close to flammable materials. -
Page 11: Meandering Welding Currents
Operating the device on a grid without a ground conductor and in a socket without a ground conductor contact will be deemed gross negligence. The manufacturer shall not be held liable for any damage arising from such usage. If necessary, provide an adequate earth connection for the workpiece. Switch off unused devices. -
Page 12: Emf Measures
either radio or television receivers). If this is the case, then the operator is obliged to take appropriate action to rectify the situ- ation. Check and evaluate the immunity to interference of nearby devices according to national and international regulations. Examples of equipment that may be susceptible to interfer- ence from the device include: Safety devices Power, signal and data transfer lines... -
Page 13: Factors Affecting Welding Results
Never touch the workpiece during or after welding - risk of burns. Slag can jump off cooling workpieces. The specified protective equipment must therefore also be worn when reworking workpieces, and steps must be taken to ensure that other people are also adequately protected. Welding torches and other parts with a high operating temperature must be allowed to cool down before handling. -
Page 14: Danger From Escaping Shielding Gas
Protect shielding gas cylinders containing compressed gas from excessive heat, mechan- ical impact, slag, naked flames, sparks and arcs. Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over. Keep the shielding gas cylinders well away from any welding or other electrical circuits. Never hang a welding torch on a shielding gas cylinder. -
Page 15: Safety Measures In Normal Operation
Before transporting the device, allow coolant to drain completely and detach the following components: Wirefeeder Wirespool Shielding gas cylinder After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service technicians before com- missioning the device. -
Page 16: Safety Inspection
(e.g. relevant product standards of the EN 60 974 se- ries). Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following address: http://www.fronius.com... -
Page 17: General
The VR 1500 - 30 is also used for flat wire applications. In particular, the VR 1500 - 11, VR 1500 - 12 and VR 1500 - 30 are also used in conjunction with the high performance TS / TPS 7200 and TPS 9000 power sources. -
Page 18: Warning Notices On The Device
Warning notices The wire-feed unit has safety symbols on the rating plate. The safety symbols must not be on the device removed or painted over. The symbols warn against operating the equipment incorrectly, as this may result in serious injury and damage. Do not use the functions described here until you have fully read and understood the following documents: These operating instructions... -
Page 19: Options
WARNING! An electric shock can be fatal. If you do not use the optional VR 1500 adapter plate, the wirefeeder must be mounted in such a way that it is insulated from earth. VR 1500 torch support... -
Page 20: Optional Installation And Conversion Kits
Optional installa- 900 A VR 1500 installation kit (VR 1500 - 11, VR 1500 - 12 and VR 1500 - 30 only, tion and conver- each with Fronius central connector F++) sion kits for subsequent retrofitting so that the VR 1500 - 11, VR 1500 - 12 and VR 1500 - 30 are suitable for a welding current of 900 A (incl. - Page 21 ► The control unit must be earthed ► The motor plate must be insulated 3-roller wire straightening section Tuchel plug VR 1500 wire end sensor (incl. spool cover) VR 1500 wire end sensor (for welding wire drum without control cable)
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Page 22: Controls, Connections And Mechanical Components
(13) (12) (10) Front of VR 1500 / VR 1550 Front of VR 1500 - 11 / 12 / 30 Blanking cover / gas pressure sensor adjusting button (optional) Water return connection (red) Gas test button for setting the required gas flow rate on the pressure regulator. If you press and hold this button, gas will flow. -
Page 23: Rear Of Wire-Feed Unit
(10) (16) (15)(14)(13) (12) (11) (10) (9) Rear of VR 1500 / VR 1550 Rear of VR 1500 - 11 / 12 / 30 LocalNet connection - interconnecting hosepack LocalNet connection standardised connection socket for system extensions (e.g. remote control, etc.) - Page 24 (15) Blanking cover/AIR IN "torch blow out" connection (high end option, max. 15 bar) (16) Additional filter...
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Page 25: Notes Regarding The Operation Of The Vr 1500 - 11 And Vr 1500 - 12
NOTE! feeder motor The VR 1500 - 11, VR 1500 - 12 and VR 1500 - 30 wirefeeders are equipped with a wa- ter-cooled electric motor with shrunk-on-disc rotor and may only be operated in conjunction with an FK 4000 R, FK 4000 R US or FK 9000 R cooling unit. -
Page 26: Operating The Vr 1500 - 12
(55 V DC, 8 A). Operating the VR NOTE! 1500 - 12 with an unreeling wire- To operate the VR 1500 - 12 with an unreeling wirefeeder, the VR 1500 - 12 must be feeder equipped with an increased motor supply installation kit. -
Page 27: Connecting Wire-Feed Unit To Power Source
"O" position Fix the strain-relief device of the interconnecting hosepack to the VR 1500 hosepack holder Connect the gas hose of the interconnecting hosepack to the shielding gas connection... - Page 28 VR 1500 / VR 1550: connect the interconnecting hosepack to the wirefeeder Interconnecting hosepack; wirefeeder end blue (11) (10) VR 1500 - 11 / 12 / 30: Connecting the interconnecting hosepack to the wirefeeder Interconnecting hosepack; wirefeeder end 2nd power cable (optional) blue...
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Page 29: Fitting The Welding Torch
(X) ... up to a max. of 500 A NOTE! When using a welding current over 500 A, only operate the VR 1500 - 11, VR 1500 - 12 and VR 1500 - 30 wirefeeders with adequately dimensioned Fronius welding torches that have F++ connections. -
Page 30: Fitting The Welding Torch - Tweco Connection
Fitting the weld- turn the power source mains switch to ing torch - Tweco the "O" position connection Check that the welding torch is correc- tly set up. Insert it - infeed tube first - into the torch connection (1) Inserting the welding torch into the connection for Twe- Fix the welding torch in place using a knurled screw (2) -
Page 31: Inserting/Replacing Feed Rollers
Inserting/replacing feed rollers General remarks In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded. IMPORTANT! Only use feed rollers that match the wire electrode. An overview of the feed rollers available and their possible areas of use can be found in the spare parts lists. -
Page 32: Feeding In The Wire Electrode
Feeding in the wire electrode Insulated routing WARNING! of wire electrode to wire-feed unit Risk of serious injury and property damage or an inferior weld as a result of earth contact or short-circuit of a non-insulated wire electrode. In the case of automated applications, ensure that only an insulated wire electrode is rout- ed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder (e.g. -
Page 33: Set The Contact Pressure
CAUTION! Risk of injury from wire electrode emerging at speed. When pressing the wire threading button or the torch trigger, keep the welding torch away from your face and body, and wear suitable protective goggles. Set the contact NOTE! pressure Set the contact pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeeding. - Page 34 Contact pressure standard values Aluminium 3.5 - 4.5 Steel 3 - 4 CrNi 3 - 4 Feed rollers: SC = Semi-cylindrical rollers TR = Trapeze rollers PL = Plastic rollers...
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Page 35: Troubleshooting
Troubleshooting "Wire end" error The "wire end" error message is used for the following errors on VR 1500 series systems: message wire end overheating of power electronics motor current too high "Wire end" spe- Two options can be preset on the power source for the "wire end" error message: cial function complete welding ... -
Page 36: Care, Maintenance And Disposal
Care, maintenance and disposal General remarks Under normal operating conditions, the wire-feed unit requires only a minimum of care and maintenance. However, some important points must be noted to ensure that the welding system remains in a usable condition for many years. WARNING! An electric shock can be fatal. -
Page 37: Technical Data
Technical data General remarks NOTE! The specified degree of protection is only guaranteed if the VR 1500 "cover" instal- lation kit is installed. VR 1500 Supply voltage 55 V DC Nominal current Wire diameter 0.8 - 1.6 mm 0.03 - 0.06 in. - Page 38 Coolant Original Fronius coolant Maximum coolant pressure 6 bar 87 psi. VR 1500 - 12 Supply voltage 55 V DC Nominal current Wire diameter 0.8 - 3.2 mm 0.03 - 0.13 in. Wire feed speed 0.5 - 12 m/min 19.69 - 472.44 ipm.
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Page 39: Vr 1550 (Cmt-Ws)
Dimensions l x w x h 405 x 208 x 205 mm 15.75 x 8.19 x 8.07 in. Weight 7 kg 15.43 Ib. Drive 4-roller drive Maximum shielding gas pressure 7 bar 101 psi. Coolant Original Fronius coolant Maximum coolant pressure 6 bar 87 psi. -
Page 41: Appendix
Appendix... -
Page 42: Spare Parts List: Vr 1500, Vr 1550
Spare parts list: VR 1500, VR 1550... - Page 49 Connection hose pack W 4m 95mm² 4,047,291 W 8m 95mm² 4,047,292 W 8m 95mm² 4,047,292,800 ** W 10m 95mm² 4,047,396 32,0405,0226 42,0407,0482 40,0001,0095 - * 42,0405,0239 42,0407,0482 42,0407,0063 32,0405,0226 42,0402,0053 40,0001,0012 - * 42,0001,0942 42,0001,0943 42,0405,0239 44,0450,0281 - G 1/4" 43,0003,0251 43,0003,0253 42,0407,0048...
- Page 50 Verb. Schlauchpaket W 25M 95mm² 4,047,326 Verb. Schlauchpaket W 30M 95mm² 4,047,321 32,0405,0226 42,0407,0482 40,0001,0095 specify length 42,0405,0239 42,0407,0482 42,0407,0442 32,0405,0226 42,0402,0053 40,0001,0008 42,0001,1990 specify length 42,0001,0943 42,0405,0239 G 1/4" - 44,0450,0281 42,0407,0442 43,0003,0251 42,0407,0063 43,0003,0253 40,0001,0012 42,0407,0048 44,0001,0971 specify length 40,0003,0447 specify length 44,0450,0281...
- Page 51 Connection hose pack G 50mm² 4m 4,047,411 G 70mm² 8m 4,047,412 32,0405,0226 42,0407,0482 40,0001,0095 - * 42,0405,0239 42,0407,0482 32,0405,0226 44,0450,0281 - G 1/4" 42,0407,0063 43,0003,0251 40,0001,0012 - * 43,0003,0253 42,0405,0239 42,0407,0048 40,0003,0447 - * 42,0407,0063 44,0450,0281 - G 1/4" 43,0003,0063 - 50mm² 43,0003,0064 - 70mm²...
- Page 52 Connection hose pack G 50mm² 1,2m 4,047,408 G 50mm² 5m 4,047,409 G 50mm² 10m 4,047,410 32,0405,0226 42,0407,0482 40,0001,0095 - * 42,0405,0239 42,0407,0482 44,0450,0281 - G 1/4" 32,0405,0226 42,0407,0063 43,0003,0485 40,0001,0012 - * 32,0405,0232 42,0405,0239 32,0405,0180 42,0407,0048 40,0003,0078 - * 42,0407,0063 44,0450,0281 - G 1/4"...
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Page 53: Circuit Diagrams: Vr 1500, Vr 1500 Psa, Vr 1550
Circuit diagrams: VR 1500, VR 1500 PSA, VR 1550 VR 1500... - Page 54 VR 1500 PSA...
- Page 55 VR 1550 / VR 1550 CMT-WS...
- Page 56 FRONIUS INTERNATIONAL GMBH Vorchdorfer Straße 40, A-4643 Pettenbach, Austria E-Mail: sales@fronius.com www.fronius.com Under www.fronius.com/contact you will find the addresses of all Fronius Sales & Service Partners and locations...
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